Insulating composition.



UNITED STATES PATENT oEFIcE;

Lab II. Barnum), or rename, new Yonx, Assmn'oa 'ro clmnn'u. 3.41a

' COMPANY, 01 YORK, 11'. Y., A COBPOBLTIUI '01 NEW YORK.

m'snnarmd comrosrrrou.

Compositions, of which the following is a specification.

This invention relates to more or less' fluid or mobile compositions containing phenolic condensation products, particularly such as are transformable by simple heating to the infusible state, in which state they may however retain under some conditions a marked degree of elasticity, particularly at higher temperatures.

It is now well understood in the art that there exist two Well-defined groups of phenolic condensation products, viz., those which are initially" soluble and fusible but which are transformed by simple heating to infusible bodies, passing in the course of such transformation through an intermediate state in which they areplastic but infusible, and gelatinized by certain organic liquids but insoluble therein: and those which are: permanently fusible and soluble in various solvents, particularly in the presence of free phenols. It is also known that the productsof the second group, which have been variously designated as saliretins or saliretin-resins, novolak, shellac substitutes,

phenol resins, etc., and which intheir properties more closely approximate the natural resins, may be transformed by the action of formaldehyde, or other bodies containing a 'mobile methylene group, into the products of the first (See U. S. Patents group.

1,038,475 to L. H. Baekeland, 1,020,593 to.

J. W. Aylsworth, Belgian Patent 204,811 to Knoll.)

My invention relates particularly to the preparation of solutions of initial condensation products of the first group, the object of the invention being to prepare solutions which neither contain, in any material proportion, nor yield by reaction, bodies such as water, ammonia, methyl or ethyl alcohol, acetone, water soluble bodies, or substances which attract or retain ammonia or water, acid-reacting substances, or the like, or in general any substance which would lessen the valueof the solution, or of the product obtained by hardening the same, for elec- Speciflcation of Letters hunt.

No Drawing. Original application me October 1?, 191:, Serial no. mare. Divided and this application filed January 26, 1915. Serial 1'0. 4,554.

are claimed in a copen Patented Feb. 20, 1917.

trical insulating purposes, particularly where highfrequency. alternating currents of such solutions or compositions. a novel phenolic condensation product, which prod uct and'the method of (preparing the same,

rial No. 7 7 6,847,, filed July 1, 1913, by Backeland and Gotthelf.

One composition in accordance with the ng application Sepresent invention may be prepared as follows I incorporate with a suitable solvent, preferably having the characteristics hereinafter pointed out, suitable proportions of a fusible phenolic resin (a fusible phenolic condensation product of the second group above referred. to)- and of anhydro-formaldehydeanilin. These reacting components may be added to. the solvent either separately or mixed together, or they ma be melted or sintered together before belng introduced into the solvent. In any case, the resulting mixture is heated to a degree suflicient to obtain a good solution. In ordinary practice, the proportion of anhydro-form'alde hyde-anilin to 100 parts of the fusible phenolic resin may vary from 20 to 200 parts. The proportion of these combined ingredients to the solvent may vary within Wide limits up to complete saturation according to the use to which the solution is to be applied.

.Anhydro formaldehyde anilin possesses mobile methylene groups, and is hence capable of converting the fusible phenol resins of the second group into the products of the first group, which latter upon sufficient heating are transformed into infusible bodies. The particular advantage possessed by anhydro-formaldehyde-anllin in this reaction resides in the fact that in contradistinction to all such methylene-containing bodies as formaldehyde, its polymers and hydrates, the methylene amins, including hexamethylene-tetramin, methylene combinations with halogens, alcohol groups,-

,is particularly advantageous in the case of products intended for the insulation of high tension alternating currents, where even the smallest traces of water, ammonia, substances which retain water or ammoma, or are soluble in water, acid-reacting substances, etc, are highly prejudicial. It is hence highly desirable to provide a solvent which Wlll not detract from the value of the product as an insulator. For this purpose therefore the choice of a proper solvent is restricted to bodies possessing the following charactenstics, viz. i

(1) The capacity of dissolvmg the mltlal condensation product without the addition or presence of free phenol or cresol, methyl or ethyl alcohol, acetone, esters, nitrobenzol, etc, or of other compounds of lower insulating value than the solvent ltsel f;

(2) Lack of ailinity for water as evidenced by substantial immiscibility therewith;

(3) High insulating value, for high tension alternating currents, and freedom from any too pronounced tendency to become heated under the action of such currents.

1L satisfactory solvent having these characteristics is so-called neutral oil, which is understood to be a high-boiling-point distillate from gas tar, freed by treatment with acids and caustic alkalis from tar acids and bases, such as phenol, cresol, ammonia, pyridin, or the like, and containing in varying proportions certain highboiling cyclic hydrocarbons. A suitable neutral oil for this purpose is one of which about ninety per cent. by volume distils between 135 and 340 (3., the higher boiling fractions being preferred. Other appropriate solvents for electrical purposes are for instance, mono-chlor-naphthalene, tetrachlorethane (boiling point about 147 0.), chloroform, dichlorethylene (boiling point about 55 C.), ethylene-chlorid or symmetrical dichlorethane (Dutch liquid) (boilingpoint about 84 0.), said solvents being used alone, or mixed, or in conjunction with varying proportions of benzol or its homologues or other suitable hydrocarbons.

F or many purposes, as more fully explained below preference is given to those solvents which have a boiling-point exceeding that of water.

For the preparation of compositions intended for electrical insulation it is well to observe the precaution of freeing the fusible phenolic resin from any considerable excess of phenol or cresol by washing with water, steaming, or otherwise, and then rendering itquite anhydrous by sufiicient heating.

The proportion of anhydro-formaldehydeanilin used exerts a profound influence upon the character of the condensation product, and this proportion may therefore be widely varied according to the nature of the product desired. Condensation products containing up to 20 parts by weight of anhydro-formaldehyde-anilin to 100 parts of the fusible phenol resin are in general permanently fusible. The higher proportions of anhydro-formaldehyde-anilin, up to 200 parts by weight for 100 parts of the fusible phenolic resin, yield products which ultimately become infusible under continued heating. The hardness of these infusiblc products tends to increase up to about 110 to 130 parts of anhydro-formaldehyde-anilin to 100 parts of the fusible phenolic resin, while products prepared with still higher proportions of anhydro-formaldehyde-anilin, show increased plasticity at higher temperaturcs.

The resistance of the infusible products to the action of such chemicals as alcohol, acetone and dilute caustic soda, increases with the proportion of anhydro-formaldehyde-anilin used. For example, products containing from 150 to 200 parts of anhydro-formaldehyde-anilin to 100 parts of fusible phenolic resin, were not apparently acted upon by 10% caustic soda solutions, or by methyl alcohol, after eleven days at room temperatures, and were only slightly softened by acetone.

It is to be understood thatmodifications of my method which involve the formation in the solvent of the anhydro-formaldehydeanilin, or of the fusible phenolic resin, or both, from their components, are within the scope of my invention. Such methods I now regard as less desirable than the direct method above described, according to which the pre-formed fusible phenolic resin and anhydro formaldehyde anilin are incorporated with the solvent, separatcly or after being sintered or melted together or combined by heat.

My invention is not restricted to the use of the solvents above mentioned as particularly desirable for purposes of electrical insulation, for I may employ various solvents or mixtures of solvents according to the use for which the composition is designed. Among such uses are The impregnation, filling or coating of coils, for electrical purposes, and the insulation of electrical conductors;

The impregnation of wood, paper, woodpulp, cement, porous stone and other porous materials;

The coating of paper and the preparation of composite cardboard;

The preparation of putties, cements, and analogous compositions; I

The preparation of protective enamels, fiiatings, varnishes, paints, lacquers and the The manufacture of molding mixtures and molded articles.

For the impregnation of coils, the manu.

facture of putties and cements, and other uses in which it is desired that little or no evaporation should occur, it isdesirable to select a solvent of which the boiling-point is sufliciently high to ermit the reaction whereby the product 1s transformed to its infusiblc state to occur without the solvent being expelled, Typical solvents of this class are neutral oi and mono-chlor-naphthalene. Heat should be applied to obtain complete solution. About equal parts by weight of condensation product and one of the above solvents, gives a composition of about the required consistency for most purposes, although these proportions may be altered considerably to meet the particular requirements. Greater or lesser amounts of any of the more readily volatile auxiliary solvents may be added, the highboiling solvent constltuting, however, the main part of the solvent. Solutions containing about 50% by weight of neutral oil or mono-chlor-naphthalene will gelatinize to an elastic, infusible mass if heated for about 10 hours at about 110 to 115 0.; further heating at these or somewhat higher temperatures, renders the mass still firmer and harder.

When varnishes, paints and lacquers are to be prepared, the solvent should ossess sufficient volatility to permit ready rying; and when the varnish is to be applied for electrical insulation, the solvent should possess the characteristics above set forth. Typical solvents for such uses are ethylenechlorid (boiling-point about 84 C.) ,d1chlorethylene (boiling-point about 55 C.), and chloroform, used alone or mixed, or suitably diluted with benzol. a

If symmetrical dichlorethane (Dutch liquid, chlorid of ethylene) be used as a solvent, it'can be diluted with as much as three or four times its own volume of benzol. Chloroform can stand an addition of about an equal volume of benzol, dichlorethylene, about two volumes, and tetrachlorethane about two to three volumes.

Toluene can be used as a diluent only in smaller roportions than benzol.

-Satis actory solutions, applicable for use as varnishes or lacquers, or when mixed with suitable pigments as vehicles for paints, may be prepared by compounding, wlth aid of heat if necessary, approximately equal amounts of solvent and solute; for example, if chlorid of ethylene (symmetrical dichlorethane or Dutch liquid) and the above condensation product, prepared with anhydroformaldehyde-anilin, while it is yet in its soluble condition, be compounded in about equal proportions by Wei ht, the resulting solution can be diluted as a ove indicated, as may be required for particular uses, or more vide a solution in a solvent of such high insulating value as is herein contemplated, of any initial phenolic condensation prod- ;uct which is capable of transformation by simple heating into an infusible body. I am aware that it has been alleged that condensation products prepared without the use of anhydro-formaldehyde-anilin may be dissolved -in benzol, toluol or mono-chlornaphthalene, but I have found that this solution is dependent upon the presence of. considerable proportions of free phenols, or nitrobenzol, or acetone or other ketones, alcohol, esters, or similar auxiliary solvents, which greatly reduce the availability of the resultingsolution for purposes of electrical insulation.

In the preparation of industrial products and compositions consisting of or containing the compositions above described it is to be understood that -I may incorporate such substances, as for example those of 'a fibrous or cellular nature, or powdered fillers or substances formin solid solutions, as are desirable for particular purposes; heat and pressure to any required degree may be employed for hardening or molding operations; and in general I may apply such manipulations and devices and provide such additions as are now used in this art.

The expression reaction product of phenols and anhydro-formaldehyde-anilin is used herein to include products formed by the direct reaction of phenolic bodies or of fusible phenolic resins with pre-formed anhydro-formaldehyde-anilin, and also similar products produced by the reaction of phenolic bodies or of fusible phenolic resins with anilin and formaldeh de, or with substances equivalent to these ln-the reaction.

The expression an initial phenolic condensation product capable of transformation by simple heating into an infusible body is used herein to designate those phenolic condensation products which, as above described, are dlrectly transformed by heat into infusible bodies without addition of formaldehyde or other body containing mobile methylene group. I

he present application is a division of my prior application Serial No. 7 95,779, filed October 17, 1913, insulating composition.

I claim 1. An electrical insulating composition comprising an initial phenolic condensation product capable 'of t 'ansforination by simple heating into an infusible body, and achlorinaimed-hydrocarbon solvent therefor, said solvent characterized by its high insulating value, its immiscibility with water, and its capability of dissolving the said initial condensation product after the same has been substantially freed from uncombined phenols.

'2. An electrical insulating composition comprising an initial phenolic condensation product capable of transformation by simple heating into an infusiblc body, and a chlorinated hydrocarbon solvent therefor, said solvent characterized by its high insulating value. its innniscibility with water, and its capability of dissolving the said initial condensation product after the same has been substantially freed from uncombined phenols, and having a boiling-point not exceeding that of water.

A composition comprising an initial phenolic condensation product capable of transformation by simple heating into an infusible body, and symmetrical dichlorethane.

4. A composition comp-rising a reaction product of phenols and anhydro-formaldehyde-anilin and a chlorinated-hydrocarbon solvent therefor.

5. A composition comprising a reaction product of phenols and anhydro-formaldehyde-anilin, transformable by simple heating into an infusible body, and a chlorinated-hydrocarbon solvent therefor.

6. A composition comprising a reaction product of phenols and anhydro-formaldehyde-anilin and symmetrical dichlorcthane.

7. A composition comprising a reaction product of phenols and anhydro-formaldehyde-anilin transformable by simple heating into an infusible body and symmetrical dichlorethane.

8. A composition comp-rising a phenolic condensation product, and a solvent therefor, said solvent containing symmetrical dichlorethane.

In testimony whereof I aflix my signature in presence of two witnesses.

LEO H. BAEKELAND. VVitncsses:

CIIAs. H. HALL, A. R. BRENNECKE. 

